P
US7438970B2ExpiredUtilityPatentIndex 92

Carbon fiber composite material and method of producing the same, carbon fiber-metal composite material and method of producing the same, and carbon fiber-nonmetal composite material and method of producing the same

Assignee: NISSIN KOGYO KKPriority: May 24, 2004Filed: May 23, 2005Granted: Oct 21, 2008
Est. expiryMay 24, 2024(expired)· nominal 20-yr term from priority
Inventors:MAGARIO AKIRANOGUCHI TORU
C08J 5/005C08K 2201/011Y10T428/249945B82Y 30/00Y10T428/24994Y10T428/249924B29C 70/00C08K 7/24C08J 5/042C08K 7/06C08K 9/02C08K 2201/003
92
PatentIndex Score
29
Cited by
35
References
37
Claims

Abstract

A carbon fiber composite material including: a thermoplastic resin; carbon nanofibers dispersed in the thermoplastic resin; and dispersing particles which promote dispersion of the carbon nanofibers in the thermoplastic resin.

Claims

exact text as granted — not AI-modified
1. A carbon fiber composite material, comprising:
 a thermoplastic resin; 
 carbon nanofibers dispersed in the thermoplastic resin; and 
 dispersing particles which promote dispersion of the carbon nanofibers in the thermoplastic resin: 
 
       wherein:
 the carbon fiber composite material has a first-component spin-spin relaxation time (T 2   s ) of from 100 to 1,000 μsec. as measured at 250° C.; 
 the carbon fiber composite lacks or has a second-component spin-spin relaxation time (T 2   l ); 
 the fraction of components having the second-component spin-spin relaxation time is less than 0.2, as measured at 250° C. by Hahn-echo method using a pulsed NMR technique with  1 H as an observing nucleus; and 
 if the carbon fiber composite has a second-component spin-spin relaxation time (T 2   l ), (T 2   l ) is less than 20,000 μsec. 
 
     
     
       2. The carbon fiber composite material as defined in  claim 1 , wherein an amount of the dispersing particles is 1 to 2,000 parts by weight for 100 parts by weight of the thermoplastic resin. 
     
     
       3. The carbon fiber composite material as defined in  claim 1 , wherein the dispersing particles have an average particle diameter greater than an average diameter of the carbon nanofibers. 
     
     
       4. The carbon fiber composite material as defined in  claim 1 , wherein the dispersing particles have an average particle diameter of 500 μm or less. 
     
     
       5. The carbon fiber composite material as defined in  claim 1 , wherein the dispersing particles are metal particles. 
     
     
       6. The carbon fiber composite material as defined in  claim 1 , wherein the dispersing particles are nonmetal particles. 
     
     
       7. The carbon fiber composite material as defined in  claim 5 , wherein the metal particles are selected from the group consisting of: aluminum, aluminum alloys, magnesium. magnesium alloys, titanium, and titanium alloys. 
     
     
       8. The carbon fiber composite material as defined in  claim 1 , wherein the carbon nanofibers have an average diameter of 0.5 to 500 nm. 
     
     
       9. A carbon fiber-metal composite material obtained by replacing the thermoplastic resin in the carbon fiber composite material as defined in  claim 1  with a metal matrix material. 
     
     
       10. A carbon fiber-nonmetal composite material obtained by replacing the thermoplastic resin in the carbon fiber composite material as defined in  claim 1  with a nonmetal matrix material. 
     
     
       11. A method of producing a carbon fiber composite material, the method comprising:
 (a) mixing a thermoplastic resin and dispersing particles which promote dispersion of carbon nanofibers in the thermoplastic resin; and 
 (b) mixing the carbon nanofibers into the thermoplastic resin including the dispersing particles and dispersing the carbon nanofibers by applying a shear force; 
 
       wherein:
 the carbon fiber composite material has a first-component spin-spin relaxation time (T 2   s ) of from 100 to 1.000 μsec, as measured at 250° C.; 
 the carbon fiber composite lacks or has a second-component spin-spin relaxation time (T 2   l ); 
 the fraction of components having the second-component spin-spin relaxation time is less than 0.2, as measured at 250° C. by Hahn-echo method using a pulsed NMR technique with  1 H as an observing nucleus; and 
 if the carbon fiber composite has a second-component spin-spin relaxation time (T 2   l ). (T 2   l ) is less than 20,000 μsec. 
 
     
     
       12. The method of producing a carbon fiber composite material as defined in  claim 11 , wherein an amount of the dispersing particles is 1 to 2,000 parts by weight for 100 parts by weight of the thermoplastic resin. 
     
     
       13. The method of producing a carbon fiber composite material as defined in  claim 11 , wherein the dispersing particles have an average particle diameter greater than an average diameter of the carbon nanofibers. 
     
     
       14. The method of producing a carbon fiber composite material as defined in  claim 11 , wherein the dispersing particles have an average particle diameter of 500 μm or less. 
     
     
       15. The method of producing a carbon fiber composite material as defined in  claim 11 , wherein the dispersing particles are metal particles. 
     
     
       16. The method of producing a carbon fiber composite material as defined in  claim 11 , wherein the dispersing particles are nonmetal particles. 
     
     
       17. The method of producing a carbon fiber composite material as defined in  claim 15 , wherein the metal particles selected from the group consisting of: aluminum, aluminum alloys, magnesium, magnesium alloys, titanium, and titanium alloys. 
     
     
       18. The method of producing a carbon fiber composite material as defined in  claim 11 , wherein the thermoplastic resin has a molecular weight of 10,000 to 1,000,000. 
     
     
       19. The method of producing a carbon fiber composite material as defined in  claim 11 , wherein the thermoplastic resin has a first-component spin-spin relaxation time (T 2   s ) of 100 to 50,000 μsec at a temperature of the step (b), the first-component spin-spin relaxation time being measured by a Hahn-echo method using a pulsed nuclear magnetic resonance (NMR) technique. 
     
     
       20. The method of producing a carbon fiber composite material as defined in  claim 11 , wherein the thermoplastic resin has a spin-lattice relaxation time (T 1 ) of 10 to 5,000 msec at a temperature of the step (b), the spin-lattice relaxation time being measured by a Hahn-echo method using a pulsed nuclear magnetic resonance technique. 
     
     
       21. The method of producing a carbon fiber composite material as defined in  claim 11 , wherein the carbon nanofibers have an average diameter of 0.5 to 500 nm. 
     
     
       22. The method of producing a carbon fiber composite material as defined in  claim 11 , wherein the step (b) is performed by an open-roll method. 
     
     
       23. The method of producing a carbon fiber composite material as defined in  claim 11 , wherein the step (b) is performed by an internal mixing method. 
     
     
       24. The method of producing a carbon fiber composite material as defined in  claim 11 , wherein the step (b) is performed by a multi-screw extrusion kneading method. 
     
     
       25. A method of producing a carbon fiber-metal composite material, the method comprising:
 (c-1) replacing the thermoplastic resin in the carbon fiber composite material obtained by the method as defined in  claim 11 , with a metal matrix material. 
 
     
     
       26. A method of producing a carbon fiber-nonmetal composite material, the method comprising:
 (c-2) replacing the thermoplastic resin in the carbon fiber composite material obtained by the method as defined in  claim 11 , with a nonmetal matrix material. 
 
     
     
       27. The method of producing a carbon fiber-metal composite material as defined in  claim 25 , wherein the step (c-1) includes powder forming. 
     
     
       28. The method of producing a carbon fiber-nonmetal composite material as defined in  claim 26 , wherein the step (c-2) includes powder forming. 
     
     
       29. The method of producing a carbon fiber-metal composite material as defined in  claim 25 , wherein the step (c-1) includes mixing the carbon fiber composite material into a molten metal and casting the resulting mixture in a die having a desired shape. 
     
     
       30. The method of producing a carbon fiber-nonmetal composite material as defined in  claim 26 , wherein the step (c-2) includes mixing the carbon fiber composite material into a molten nonmetal and casting the resulting mixture in a die having a desired shape. 
     
     
       31. The method of producing a carbon fiber-metal composite material as defined in  claim 25 , wherein the step (c-1) includes:
 disposing a metal ingot above the carbon fiber composite material; and 
 heating the metal ingot to melt into a molten metal and heating the carbon fiber composite material to vaporize the thermoplastic resin in the carbon fiber composite material, thereby causing the molten metal to permeate the carbon fiber composite material to replace the thermoplastic resin with the molten metal. 
 
     
     
       32. The method of producing a carbon fiber-nonmetal composite material as defined in  claim 26 , wherein the step (c-2) includes:
 disposing a nonmetal body above the carbon fiber composite material; and 
 heating the nonmetal body to melt into a molten nonmetal and heating the carbon fiber composite material to vaporize the thermoplastic resin in the carbon fiber composite material, thereby causing the molten nonmetal to permeate the carbon fiber composite material to replace the thermoplastic resin with the molten nonmetal. 
 
     
     
       33. The method of producing a carbon fiber-metal composite material as defined in  claim 25 , wherein the matrix material is a material the same as a material for the dispersing particles. 
     
     
       34. The method of producing a carbon fiber-nonmetal composite material as defined in  claim 26 , wherein the matrix material is a material the same as a material for the dispersing particles. 
     
     
       35. A carbon fiber composite material formed by the method as defined in  claim 11 . 
     
     
       36. A carbon fiber-metal composite material formed by the method as defined in  claim 25 . 
     
     
       37. A carbon fiber-nonmetal composite material formed by the method as defined in  claim 26 .

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